Low Temperature Extrusion Process and Device for Energy Optimized and Viscosity Adapted Micro-Structuring of Frozen Aerated Masses

ABSTRACT

The invention describes a low temperature extrusion process and a respective device for an energy-optimized and viscosity-adapted microstructuring of frozen aerated systems like ice cream. Therewith a very finely dispersed microstructure is reached under optimized balance of viscous friction based mechanical energy dissipation (1) and transfer of dissipation heat and additional phase transition (freezing) heat (2) to a refrigerant up to very high frozen water fraction at very low temperatures. With this new process and device aerated masses are continuously frozen and optimally micro-structured under minimized/optimized mechanical energy input. The microstructure of this-like treated masses supports on the one hand preferred rheological properties which lead to improved shaping, portioning and scooping properties, even at very low temperatures, and on the other hand leads to an improved shelf life (heat shock stability) and mouth feel (e.g. creaminess, melting behavior).

The invention comprises a process for the manufacture of deeply frozendeserts in particular ice cream, under optimized conditions for theinput of mechanical energy in order to generate a homogeneous, finelydispersed microstructure and simultaneously optimized conditions for thetransfer of dissipated and phase transition (freezing) heat, up to ahigh frozen water fraction at related low temperatures, as well as adevice to run this process.

BACKGROUND OF THE INVENTION

Single and twin screw extruders are well known continuous processingapparatus which are mainly used in the polymer and ceramics but as wellin food industry where e.g. pasta and snack products are produced. Since1992 (DE 4202231 C1) extruders were also suggested to be used forcontinuous freezing of frozen deserts like ice cream.

Processing Aspects

As described in several publications (see literature review 2-19) a lowtemperature extruder allows for deep-freezing of ice cream and otherfood masses like yoghurt and fruit pulps up to a high degree of frozenwater fraction (80-90% related to the freezable water fraction) undersimultaneously acting mechanical stresses by shear flow.

The dissipated heat caused by viscous friction in the highly viscouspartially frozen systems (dynamic viscosity up to 10⁴ Pas) has to betransferred in addition to the crystallization heat (freezing)efficiently, whereas an equilibrium between generated and transferredheat is adjusting dependant on the heat transfer coefficient k(describes the heat transfer through a product layer adhering to theinner wall of the extruder housing to and through this steel wall andinto an evaporating refrigerant contacting the outer wall of theextruder barrel.

Up to now, maximum heat transfer coefficients are reached by a properchoice of extrusion screw geometries with a narrow leakage gap betweenthe extruder barrel flight tip and the inner wall of the extruder barrelin order to efficiently replace the frozen material layer next to theextruder barrel wall, and by use of an evaporating refrigerant (e.g.ammonia) for cooling of the extruder housing. The shear rates generatedin the screw channel are narrowly distributed due to the use of screwgeometries with low, constant screw channel height and a slight axialshift of the screw arrangement within twin-screw extruder systems (EP0561 118B1). This means, that there are no expanded zones with eithervery high or very low shear rates. At maximum shear rates of approx.20-30 s⁻¹ for typical ice cream masses outlet temperatures of −12 to−18° C. at the extruder outlet are reached.

The minimum draw temperature of the mass at the extruder outlet dependson the freezing point depressing properties of the mass and the relatedviscosity of the mass at respective temperature as well as on themechanical energy dissipation caused by the viscous friction.

In ice cream mass extrusion (e.g. according to patents EP 0561118, U.S.Pat. No. 5,345,781), only a small pressure gradient over the extruderlength is generated. The total pressure difference between extruder in-and outlet is in general ≦1-5 bars. This guarantees the avoidance ofde-mixing the gas liquid (foam) mixture, which is still rather lowviscous at the extruder inlet, to a large extent. The specific extruderscrew configuration as well as the screw arrangement (twin screw) in thelow temperature extruder according to EP 0561118 or U.S. Pat. No.5,345,781; DE 4202231C1 respectively in addition apply a gentle,efficient mixing of the mass. This is particularly achieved by anappropriate flow stream distribution in the screw flightoverlapping/intermeshing zone between the screws in the twin screwarrangement.

Product Aspects

Beside beforehand described apparatus and process related aspects thereis main interest in the product specific advantages properties which canbe achieved within ice cream treated by low temperature extrusion.Generally it can be stated that such advantageous properties generatedby low temperature extrusion relate to a more finely dispersing of themicro-structural ice cream components: ice crystals, air bubbles/aircells and fat globule agglomerates. The extent of such dispersingeffects also depends on the ice cream recipe. The following descriptionrelates to typical standard recipes of vanilla ice cream, however withvariations in the contents of fat/milk fat (0-16%) and in dry matter(35-43%). The advantageous special properties achieved for lowtemperature extruded ice creams are related to the main structuringdisperse elements in ice cream being the water ice crystals (1) the airbubbles/air cells (2) and the fat globule agglomerates (3) which are allmuch more finely dispersed under the high mechanical stresses acting inlaminar shear and elongation flow fields within the extruder flow underlow temperature conditions.

For ice crystals, secondary nucleation effects by crystal attrition andcrystal breakage in addition to further primary ice crystal nucleationat the inner barrel wall, nucleation lead to size reduction by a factor2-3 compared to conventional ice cream processing in freezer andsubsequent hardening tunnel. Mean air bubble/air cell size is reduced bya factor 3-5 compared to the conventional process due to increasedacting shear stresses leading to bubble/air cell break-up.

The intensity of the mechanical treatment in the extruder flow stronglydepends on mass viscosity, which is related to the frozen water fractionat a specific temperature. Over the cross section of the extruder screwchannel, which forms a narrow annular gap the shear stresses are ratherhomogeneously and narrowly distributed (now flow zones with stresspeaks). Over the extruder length, the mechanical energy input increaseswith increasing residence time of the ice cream in the extruder channelas well as with the increase of the mass viscosity as a result of anincreasing frozen water fraction.

A local destruction of the ice cream structure by too high energydissipation and related friction heat generation, is avoided atprocess/apparatus shear rates typically applied (EP 056118).

In fat containing ice creams there are fat globules with atypical mainsize of approximately 1 micron and below in globule diameter as a resultof the ice mix treatment in the liquid state within high pressureshomogenizers. Such fat globules also experience an increased mechanicaltreatment in the low temperature extrusion process. For the fat globulesthis treatment leads to de-hulling of the fat globule surface fromprotein/emulsifier membranes and partially also to a strong deformationof the fat globules by the intensive shear acting in the extruder. As aconsequence, such treated fat globules are expected to have strongerhydrophobic interactions. Consequently, there is also an increasedaffinity to the gas/air bubble interface. The increased interactionbetween treated fat globules leads to the formation of fat globuleaggregates. However, the movability of such fat globules in the highlyviscous low temperature loaded ice cream is low and consequently thereis no chance for the formation of largely expended fat globuleaggregates reaching a sensorially (mouth) detectable size. This avoidsthe generation of a buttery mouth feel causing structure.

From the sensorial view point, the smaller ice crystals and gas/airbubbles as well as the mechanically treated but not too largelyagglomerated fat globules lead to a strongly increased perceptiblecreaminess of the product. At the same time, other sensorial attributesare also significantly positively influenced by low temperatureextrusion of the ice cream like the melting behavior, the coldnesssensation in the mouth and the scoop ability.

Due to the increased fine dispersity of the disperse ice creamcomponents causing the beforehand described increase of creaminesssensation, low temperature extrusion allows to generate comparablecreaminess like conventional ice cream processing at much lower fatcontent.

Construction Aspects (Extruder Screw(s))

To generate a homogeneous microstructure of the ice cream (1) and at thesame time reach very low extruder outlet mass temperatures of lower thanca. −12° C. (2) (standard vanilla ice cream) the construction of theextruder screw(s) with respect to the related flow conditions at adaptedrotational speed are of crucial importance.

EP 561118 describes a twin screw extruder for continuousfreeze-structuring of ice cream using screw geometries, with especiallyflat screw channels (ratio channel height H to channel width W about0.1, ratio of channel height to outer screw diameter about 0.1) and ascrew angle of ca. 22 to 30°.

EP 713650 relates to a process which also includes a twin screw extruderfor the extrusion of frozen products. The screw characteristics are onlydescribed by the ratio of extruder length to screw diameter.

EP 0808577 describes a comparable process using a single screw extruderwith similar construction principles of the screw like given in EP713650.

W097/26800 claims process and apparatus for the manufacture of frozeneatable foams like ice cream using also a single screw extruder.Characteristic properties for the geometry of the extruder screw are theratios: length of the screw to inner diameter of the extruder housingbetween 5 and 10, ascending height of the screw to the screw outerdiameter between 1 and 2 as well as outer diameter of the screw to innerscrew diameter between 1.1 and 1.4. The extrusion screw has only 1 screwflight.

There are also low temperature extruders known (single and twin screwextruders) for the treatment of ice cream with 2-6 screw flights,preferably 2-5, and a screw angle of 28 to 45° preferably 32 to 45°.Preference is given to a ratio of general height to general width ofsmaller than 0.2 but larger than 0.1. Preferred ratio of screw channellength to inner screw diameter is fixed to 2 to 10, preferably 2-4. Thisleads to rather short extruders.

The basic difficulty in continuous freeze structuring of ice creamwithin low temperature extrusion systems relates to the combination of amechanical treatment and the simultaneous solidification by ongoingfreezing. The latter leads to the increase of viscous friction basedenergy dissipation proportional to the viscosity and consequently to theneed of transferring this dissipated energy in addition to thecrystallization enthalpy set free by the freezing process. This coupledheat transfer is limited by the rather low heat conductivity of thefoamed ice cream mass and the related achievable heat transfercoefficient k in the laminar low temperature extrusion flow of the icecream. The heat has to be transferred from the flowing ice cream massthrough a non-mixed inner barrel wall adhering ice cream layer, throughthe barrel wall and to the refrigerant contacting the outer barrel wall.The optimization of the flow conditions in the extruder with respect tomaximally improved product properties, aims the maximum shear treatmentto reach most finely dispersed microstructure at minimum extruder outlettemperature.

In the extruder screw geometries, conventionally described for lowtemperature extrusion processing a high mechanical treatment efficientfor micro-structuring is only reached in the end zone of the lowtemperature extruder close to the extruder outlet. The length of thisstructuring-efficient end zone reaches in general less than 50% of thetotal extruder length.

Due to the fact that, in general ice cream pre-frozen in a conventionalice cream freezer, is transferred into the low temperature extruder atinlet conditions of −5° C. and approximately 35 to 45% of freezablewater fraction frozen, this mass experiences only low shear stresses inthe extruder entrance zone up to about 50% of the extruder length. Thetreatment in this extruder domain does not contribute to finerdispersing of the microstructure components (ice crystals, airbubbles/air cells, fat globule agglomerates).

Like shown in recent research work there is even an increase in airbubble/air cell size detected in the first 30 to 50% of the extruderlength. The reason for this is the shift in the dynamic equilibriumbetween air bubble dispersing and air bubble coalescence towardsincreased contribution of the coalescence due to the lower actingmechanical stresses compared to the precedent treatment of the ice creamin the conventional freezer.

FIG. 1 shows exemplarily such an effect of the air bubble sizedevelopment along the extruder length in the first 150 mm of a pilotextruder screw channel (15% of the extruder length). In this domain themean bubble diameter is increased by approx. 25% (see also FIG. 2). Onlyafter 400 to 450 mm (≈40-45% of total length 1000 mm, 65 mm outerextrusion screw diameter and 7 mm screw channel height), the efficientfine-dispersing starts.

Experiments with various screw geometries have confirmed that aviscosity-adapted increase in shear treatment in the first 25 to 70% ofthe extruder channel length allows to improve this situation remarkablyup to negligible coarsening of the structure in the inlet zone, thusallowing for a much better use of the extruder volume.

Problem

The problem of the invention is to freeze food masses continuously tohighest possible frozen water fractions of larger than 60 to 65% of thefreezable water fraction under simultaneous mechanically inducedmicro-structuring of the disperse components like ice crystals, airbubbles/air cells and fat globules/fat globule aggregates down tocharacteristic mean diameters below about 10 microns and narrow diameterdistributions (x_(90,3)/x_(10,3)≦10).

A further problem is to provide a device to carry out such a process.

Solution of the Problems

The problems are fulfilled by the characteristics given in the patentclaims 1 and 14.

Further Solutions

Further inventive modifications of the invention are described in thepatent claims 2-13 and 15-29.

Advantages

With the inventive process, ice cream masses can be continuously deeplyfrozen and similarly optimally micro-structured at minimizedenergy—/power input not possible before. This is enabled by optimizedheat transfer conditions from the ice cream mass to the evaporatingrefrigerant, up to high frozen mass fractions of 80-90% of the freezablewater fraction and very low related temperatures at the outlet of theinventive low temperature extrusion process of −12 to −18° C.

The microstructure of this-like treated frozen masses leads toadvantageous rheology which provides very good forming, shaping,portioning and scooping properties at much lower temperatures than knownbefore.

Furthermore all low temperature extruded ice cream masses can bepackaged and stored without intensive additional hardening (deepcooling), making conventional high energy consuming hardening tunnels nolonger necessary.

Another advantage relates to the possible reduction of the fraction ofexpensive ingredients, conventionally used (e.g. milk fat, emulsifiers)for optimizing consumer relevant properties like creaminess necessary inconventionally processed ice cream.

Ice cream, which is optimized according to this patent application,shows improved creaminess at much lower milk fat content (reduction3-6%) and without the need of emulsifiers. The reduction fat is ofparticular nutritional interest.

Further characteristics and advantages can be derived from thesubsequent drawings in which the invention is partly demonstrated asexamples:

It is shown in:

FIG. 1: the size distribution of bubble diameters as measured over theextruder length;

FIG. 2: the maximum bubble diameter as a function of temperature overthe extruder length;

FIG. 3: a typical temperature profile over the extruder length, measuredin the ice cream mass;

FIG. 4: the geometric construction of the leakage gap between the screwflight edge and the inner barrel wall;

FIG. 5: arrangement of 2 screws with increasing screw channel heightover the extruder length (example for screws with two screw flights);

FIG. 6: arrangement of two screws with constant screw channel height(here exemplary for screws with one screw flight);

FIG. 7: arrangement of two screws with constant screw channel height(exemplary for two screw flights);

FIG. 8: arrangement of two screws with increasing screw channel heightover the length of the extruder and similarly decreasing screw angleover the extruder length (exemplary for extrusion screws with twoflights);

FIG. 9: exemplary construction of screw with cuts in the screw flight(exemplary for 2 screw flights);

FIG. 10: arrangement of screw with cuts in the screw flight andintermeshing pins fixed at the inner barrel wall (exemplary for twoscrew flights);

FIG. 11: cross section view of arrangement of two screws with cuts inthe screw flight and intermeshing pins fixed to the inner barrel wall;

FIG. 12: comparison of maximum bubble size development over extrusionlength for two different screw configurations (configuration 1:conventional; configuration 2: according to invention, here with adaptedscrew channel height).

According to the invention the local mechanical power or energy input isadapted to the local heat transfer (heat flow rate from ice cream torefrigerant) in such a way, that a continuous reduction of thetemperature in the ice cream over the extruder length is resulting asshown in FIG. 3 and after half to two thirds of the extruder length anice cream temperature of below −11° C. (standard vanilla ice cream with10% milk fat, 36-38% total dry matter content, 100% overrun and sugarcomposition leading to about 55-65% of frozen water fraction at −11° C.)or a freezing degree of >55-60% frozen water fraction related to thefreezable water is reached.

The fine dispersing of the air bubbles/air cells (major number fractionbelow 10 μm, max. bubble size below 20μ), fat globule/fat globuleaggregates (major number fraction below 2 μm, max. fat agglomerate sizebelow 10 μm), and in particular a reduction of the ice crystalconnectivity (major number fraction smaller than 25 μm, max. ice crystaldiameter smaller than 50μ) are generated in the second half to finalthird of the extruder length at ice cream temperatures below ≦11° C. orfrozen water fractions of respectably ≧60% (related to the freezablewater fraction) by the shear stresses generated in the flow.

In order to reach such a final finely dispersed micro-structuring statein the extruder, the dispersing history in the inlet zone up to thesecond third of the extruder length is of major importance. A maximumefficient pre-dispersing in this part of the extruder is required, inparticular for the air bubbles/air cells. Similarly the formation of icecrystal aggregates should be reduced or avoided. For this purpose, asufficiently high mechanical energy/power input and related dispersingstresses are required.

With increasing cooling/freezing and related increase of ice creamviscosity, according to the invention, the energy/power input is adaptedby variable adjusted screw geometry for locally optimized heat transfer.Influencing variables are rotational screw velocity (1), ice cream layerthickness (2), ice cream density (3) and ice cream viscosity (4). Foroptimized heat transfer it is required to increase 1 and 3 and decrease2 and 4 as far as possible. 3 is mainly influenced by the locally actingpressure in the extruder screw channel. 4 increases along the extruderchannel as a consequence of the increase of frozen water fraction. 1 and2 are also locally optimized according to the invention by adapting thescrew geometry under given rotational speed conditions according to theinventive concept of the energy optimized and Viscosity AdaptedMicro-structuring (VAM-concept).

This concept intends to optimize the local flow fields in the extruder,with the aim to minimize power input and at the same time maximizedispersing efficiency of the disperse structure components of the icecream and furthermore maximize mixing efficiency in order to optimizethe convection supported heat transfer.

The constructive implementation of this concept into low temperatureextruders can surprisingly simply be adapted as shown from experimentsby: minimizing of the leakage gap between outer screw flight edge andbarrel housing (1), an optimized screw flight front edge contour/profile(2), locally adapted screw channel height H (3), supported by locallyadapted number of screw flights (4) and/or locally adapted screw angle(5) and/or locally adapted cuts in the screw flights (6) or locallyadapted pins intermeshing with the cuts in the screw flights, the pinsbeing fixed to the inner barrel housing (7).

Based on experimental investigations using a special measuring andsampling technique, which allowed to measure local temperatures and icecream micro structure in each length segment of the low temperatureextruder (see list of publications: 17-20), subsequent inventiveconstructions of the extruder screw geometry have been derived. Theseconstructions go much further compared to conventionally existingconstructions for low temperature extrusion.

(1) Minimum Leakage Gap Between Screw Flight Edge and Inner Barrel Wall

Leakage gap between screw flight edge and inner barrel wall according tothis invention is fixed to <0.1 mm preferably <0.05 mm.

(2) Optimized Screw Flight Front Edge Contour/Profile

The flow of the ice cream mass at the front edge of the screw flight isstrongly influenced by the contour/profile of this edge.

FIG. 4 demonstrates an exemplary inventive construction. The flatinclination or application of a radius allows to generate a compressionflow in front of the flight edge such that the thickness of a frozen icecream layer remaining at the inner barrel wall is reduced, compared tothe flow in the case of a sharp screw flight front edge. The reductionof the ice cream adhering to the barrel wall is denoted as Δs and shownin FIG. 4.

Even a small reduction of these wall adhering layer thickness has shownto have a surprisingly strong positive impact of the heat transfer fromthe ice cream mass to the inner barrel wall. According to the inventionfor a screw flight thickness of larger than 5 mm, the leakage gap widthshould be below 0.1 mm (preferably below 0.05 mm) and inclination of theflight edge should be in the range of 30-45° over a screw flightthickness of ≧2 mm. In the case of a radius contour at the front edge ofthe screw flight, the related radius should be ≧2 mm.

(3) Locally Adapted Screw Channel Height H

A reduced screw channel height H (see FIG. 5) increases shear rateproportional to 1/H at constant rotational screw velocity. This leads toa related increase of the dispersing shear stresses. As a consequence,the percentage of mechanical energy input dissipated into viscousfriction heat is also increased. Reduced layer thickness of the icecream mass in the screw channel according to a reduced screw channelheight improves the heat transfer condition. Furthermore, with respectto flow behavior of the ice cream in the screw channel, the reduced icecream viscosity at increased shear rate (non Newtonian, shear-thinningflow behavior) has to be taken into account.

Feeding a conventionally pre-frozen ice cream in a conventional icecream freezer (standard vanilla ice cream; −5° C. approx. 35-40% frozenwater fraction, viscosity at shear rate of 1 s⁻¹ approx. 10 Pas),according to the invention, in the inlet zone of the extruder (I) aratio of screw channel height and outer screw diameter between 0.03 and0.07, in the middle of the extruder length (II) between 0.1 and 0.15 andin the final third of the extruder length (III) between 0.1 and 0.25 areadjusted.

For a twin-screw extruder used in a feasibility study with an outerscrew diameter of 65 mm, this leads to absolute heights of the screwchannel of 2-5 mm in the inlet zone (I), of 6.5 to 9 mm in the middlezone (II) up to 6.5-16.25 mm in the outlet zone (III).

From one to the other zone there can be a stepwise change in the screwchannel height but a continuous change is preferred. In the latter case,a preferred range for the angle between inner barrel wall and screw rootcontour (α) as shown in FIG. 6 is resulting between 0.4°≦α<0.7° (FIG.5).

(4) Locally Adapted Number of Screw Flights

An increase of the number of screw flights reduces the screw channelwidth reverse proportional and consequently increases the number ofresulting screw channels (see FIGS. 6 and 7). The barrel wall “wipingfrequency” is proportionally increased with the number of screw flights.This improves heat transfer (i), but increases similarly the mechanicalpower/energy input and consequently the dissipated heat (ii). The latterlimits at low temperatures and high viscosities the number of screwflights. According to the invention, the extruder is divided intominimum three segments along its length. Preferably in the first thirdof the extruder length 3-6 screw flights, in the second third 2-3 screwflights and in the final third 1-3 screw flights are preferablyinstalled.

(5) Locally Adapted Screw Angle

An increase in the screw angle θ up to 45° increases the axialself-conveying mass flow characteristics of the extruder screw and alsoenhances mixing. Mixing can further be increased for larger screwangles, which has a positive impact on the convective heat transfer.However, this has also a strong impact on the dissipated heat frommechanically induced viscous friction. Due to this an increase of massviscosity due to increased frozen water fraction is consequently alsolimiting the increase of the screw angle.

According to the invention in the inlet zone of the extruder, screwangles between 45 and 90° (preferably 45 to 60° are considered. Theextreme case of 90° means axially oriented “steering” blades which nolonger form a screw (see FIG. 8). In the middle zone of the extruderlength screw angles between 30 to 35° and in the final third of theextruder length between 25 and 30° are preferably taken into account.

(6) Locally Adapted Cuts in the Screw Flights

Local cuts in the screw flights according to FIG. 9 allow the transferof ice cream mass through these cuts, which improves mixing anddispersing as well as convective heat transfer. At the same time viscousfriction and related dissipated heat is increased. Consequently suchtreatment does only make sense if the mass viscosity is not too high.According to the invention, cuts in the screw flights are applied in theinlet zone of the extruder (up to the first ca. 20-30% of the extruderlength). The width of the cuts should be close or similar to the screwchannel height. The same rule should be valid for the non-cut parts ofthe screw flight.

(7) Intermeshing Pins Locally Adapted to the Cuts in the Screw Flights,the Pins Connected to the Inner Barrel Wall

The adaptation of pins attached to the inner barrel wall intermeshingwith the cuts in the screw flights lead to more intensive dispersingflow in the gap between the screw flight and the pin (see FIGS. 10 and11). This is of particular advantage if re-coalescence of airbubbles/air cells in the inlet zone of the extruder under low viscosityconditions shall be avoided. In a high viscosity range, the high energydissipation in such gaps is disadvantageous.

According to the invention, pins intermeshing with the cuts in theextruder screw flights are preferably installed in the first 10-20% ofthe extruder length.

FIG. 12 shows exemplary the effect of a partially optimized screwchannel height on the development of the mean bubble size of an icecream over the extruder length. A reduction of the mean bubble size byabout 20-30% in the end product has a significant improvement of thecreaminess and the melting behavior as well as on the heat shockstability of the ice cream.

The characteristics described in the summary of the patent claims aswell as in the description and the related drawings can appearseparately or in any combination within the realization of theinvention.

List of Abbreviations in FIGS. 1-12:

FIG. 1:—

FIG. 2:—

FIG. 3.—

FIG. 4:

-   -   S1, S2=layer thickness of ice cream adhering to the inner barrel        wall (S1 according to the invention, S2 conventional)    -   ΔS=reduction of adhering layer (=S2−S1)    -   V_(ax)=axial velocity component of the screw flight    -   n=r.p.m.    -   Sp=width of the screw channel    -   x,y,z=coordinates

FIG. 5:

-   -   H(z)=height of the screw channel (here: as function of the        length coordinate z)    -   De(z)=inner screw diameter (here: as function of the length        coordinate z)    -   α=angle between the inner screw contour line and the inner        barrel wall    -   θ=screw angle (between a line perpendicular to the screw axis        and a projection of the screw flight in the drawing plane)    -   δ=leakage gap height (radial difference between inner barrel        radius and outer screw flight radius)

FIG. 6:

-   -   A=distance of screw axes

FIG. 7: see above

FIG. 8:

-   -   θa=screw angle at a certain length coordinate position    -   θb=screw angle at the inlet zone screw end

FIG. 9:

-   -   b1=length of the projection of a screw flight section        perpendicular to the screw axis    -   Da=outer screw diameter    -   D=inner barrel diameter

FIG. 10:

-   -   c=radial length of intermeshing pins connected to the inner        barrel wall    -   d=axial length of intermeshing pins connected to the inner        barrel wall    -   a=projection length of screw flight section into a plane        parallel to the screw axis

FIG. 11:

-   -   f=length of the intermeshing pins at the inner barrel wall in        the circumferential direction

FIG. 12:

-   -   Config. 1=conventional extruder screw configuration    -   Config. 2=extruder screw configuration according to the        invention

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AICHE, Proc. 5th World Congress of Chemical Engineering 1996, 2, 169-175(1996)

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The Influence of Mechanical Energy Input During The Freezing of Sorbeton its Structure

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A New Low Temperature Extrusion Process for Ice Cream

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Tieftemperaturextrusion

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Extrusion: A Novel Technology for the Manufacture of Ice Cream

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Auckland, New Zealand, 30 Oct.-1 Nov. 2001

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EP 0714650

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WO 0072697 A1

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EP 0438996 A2

EP 0351476 A1

DE 4202231 C1

EP 0561118 A2

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FR 2717988 A1

DK 0082/96; WO 9726800

WO 9739637

WO 9817125; U.S. Pat. No. 5,713,209

WO 9925537

WO 9924236

1. A low temperature extrusion process for energy optimized, viscosityadapted micro-structuring of frozen aerated masses having a mechanicaltreatment of a partially frozen, aerated mass over a length of theextruder screw channel zone with respect to its local viscosity,performed such that, in each of a subsequent zone there is a dispersingof air bubbles/air cells and at a same time a temperature decrease andrelated increase of the frozen water fraction is achieved.
 2. Processaccording to claim 1 comprising a characteristic length of the zonesinto which the extruder is divided with respect to an adaptation of amechanical energy input for ongoing dispersing of air bubbles/air cellsand synchronously decreasing temperature or increase of frozen waterfraction, being one to tenfold of the outer screw diameter.
 3. Processaccording to claim 1 comprising a characteristic length of the zonesinto which the extruder is divided with respect to an adaptation of amechanical energy input for ongoing dispersing of air bubbles/air cellsand synchronously decreasing temperature or increase of frozen waterfraction, being one to tenfold of the outer screw diameter, with aconstant length of these zones along the extruder.
 4. Process accordingto claim 1 comprising a characteristic length of the zones into whichthe extruder is divided with respect to an adaptation of a mechanicalenergy input or ongoing dispersing of air bubbles/air cells andsynchronously decreasing temperature or increase of frozen waterfraction, being one to tenfold of the outer screw diameter withcharacteristic zone length adapted to the local change of the massviscosity.
 5. Process according to claim 1 comprising an adaptation ofthe processing parameters rotational screw speed, mass flow rateadjusted by a positive replacement pump installed at an extruder inletand cooling temperature at an inner wall of an extruder housing adjustedby an evaporation pressure of refrigerant used for a given extruderscrew geometry, regulated in such a way, that for a conventionalstandard vanilla ice cream mass temperature ≦11° C. or more generally afrozen water mass fractions of ca. ≧60% related to the total freezablewater fraction are achieved within a first 50-75% of a length of theextruder measured from the extruder inlet.
 6. Process according to claim1 comprising an adjustment of a mechanical mass treatment with respectto its viscosity in the related extruder zone by adapted variation ofthe screw channel height.
 7. Process according to claim 1 comprising anadjustment of a mechanical mass treatment with respect to its viscosityin a related extruder zone by adapted variation of a number of screws.8. Process according to claim 1 comprising an adjustment of a mechanicalmass treatment with respect to its viscosity in a related extruder zoneby adapted variation of a screw angle.
 9. Process according to claim 1comprising an adjustment of a mechanical mass treatment with respect toits viscosity in a related extruder zone by adapted width variation ofcuts in a screw flight(s).
 10. Process according to claim 1 comprisingan adjustment of a mechanical mass treatment with respect to itsviscosity in a related extruder zone by adjusted pins fixed at an innerextruder barrel wall in such a way that they intermesh with cuts inscrew flights.
 11. Process according to claim 1 comprising an increasingtemperature reduction and increasing frozen water fraction along theextruder length due to optimized heat transfer to an evaporatingrefrigerant contacting an outer wall of an extruder housing byminimizing a leakage gap width between an outer screw flight diameterand an inner extrusion housing diameter.
 12. Process according to claim1 comprising a decreasing mass temperature, related increasing frozenmass fraction and increasing dispersing of a microstructure along theextruder length due to optimized heat transfer to an evaporatingrefrigerant contacting an outer wall of an extruder housing bygenerating a flow pattern at an outer front end of a screw flight, whichleads to a reduction of the frozen material wall layer thickness notbeing wiped off the screw flight(s) smaller than a leakage gap width.13. Process according to claim 1 comprising a decreasing masstemperature, related increasing frozen mass fraction and increasingdispersing of a microstructure along the extruder length due tooptimized heat transfer to an evaporating refrigerant contacting anouter wall of the extruder housing by generating a flow pattern at anouter front end of a the screw flight, which leads to a reduction of thefrozen material wall layer thickness not being wiped off by the screwflight(s) smaller than a leakage gap width by adjusting a profile of ascrew flight front edge which is incline to an inner barrel wall orrounded with a well defined radius.
 14. Device for low temperatureextrusion process for energy optimized, viscosity adaptedmicro-structuring of frozen aerated masses having a mechanical treatmentof a partially frozen, aerated mass over a length of the extruder screwchannel zone with respect to its local viscosity, performed such that,in each of a subsequent zone there is a dispersing of air bubbles/aircells and at the same time temperature decrease and related increase ofthe frozen water fraction is achieved, having a variable screw geometryalong the extruder length locally adjusted according to a localviscosity with respect to efficient progressive dispersing, simultaneousprogressive temperature reduction and related freezing of water. 15.Device according to claim 14 comprising a leakage gap width betweenscrew flight and inner wall of the barrel of less than 0.1 mm. 16.Device according to claim 14 comprising a screw flight thickness between2 and 20 mm and 1: screw flight front edge inclination relative to theinner barrel wall of 10-45°.
 17. Device according to claim 14 comprisingan extruder screw channel height adjusted along the extruder length tomass viscosity whereas in the feeding zone (I) of the extruder the ratioof the screw channel height to the outer screw diameter is preferablyadjusted between 0.03 and 0.07, in the middle (length) zone (II) between0.1 and 0.15 and in the final third of the extruder length between 0.1and 0.25.
 18. Device according to claim 14 comprising a continuouslyincreasing screw channel height over the extruder length such that anunscrewed contour line of a screw root between mass inlet and outlet,with the centre length axes of the screw forms an angle of 0.03 to 0.1°.19. Device according to claim 14 comprising screw(s) comprising 3 to 7screw flights in a first third of the extruder length; with 1-4, screwflights in a second third of the extruder length and with 1-3 screwflights in a final third of the extruder length in the vicinity of anextruder outlet.
 20. Device according to claim 14 comprising aprogressive reduction of a number of screw flights over 2-10 equal orvariable length segments of the extruder, whereas the number of screwsis continuously reduced by 1-2 screw flights from segment to segment.21. Device according to claim 14 comprising screw angles in an inletzone (I) between 35 and 90°, in a middle of the extruder between 30 and45°, and in a final third of the extruder length between 20 and 35°. 22.Device according to claim 14 comprising a constant or variable screwangle reduction between 45 and 90° from an extruder inlet zone(I)—to—between 20 to 35° in an extruder outlet zone (III).
 23. Deviceaccording to claim 14 comprising cuts in the screw flights over a first10 to 30%, of the extruder length.
 24. Device according to claim 14comprising screws having more than one screw flight and cuts in therespective screw flights which are shifted axially such that the mass issubjected to scraping/“wiping off” flow at each part of an inner barrelwall.
 25. Device according to claim 14 comprising cuts in a screwflights where a length of these cuts is 2.5- to 3-fold, of a screwchannel height and where the non-cut parts of the screw flights have thesame dimensions.
 26. Device according to claim 14 comprising inbuiltelements, connected to an inner barrel wall, intermeshing with cuts in ascrew flights during screw rotation.
 27. Device according to claim 14comprising elements, connected to an inner barrel wall at 2-10 differentpositions arranged at a perimeter of an inner barrel wall.
 28. Deviceaccording to claim 14 comprising more than one screw flights having cutsin the same axial position to allow for intermeshing with inbuiltelements.
 29. A single or twin-screw extruder arrangement for lowtemperature extrusion of frozen, aerated masses and adapted geometrycharacteristics comprising a mechanical treatment of a partially frozen,aerated mass over a length of the extruder screw channel zone withrespect to its local viscosity, performed such that, in each of asubsequent zone there is a dispersing of air bubbles/air cells and atthe same time temperature decrease and related increase of the frozenwater fraction is achieved, having variable screw geometry along theextruder length locally adjusted according to a local viscosity withrespect to efficient progressive dispersing, simultaneous progressivetemperature reduction and related freezing of water.